Contoured pouch with pourable spout, and apparatus and process for producing same

ABSTRACT

The present invention relates to sealed pouches, and apparatus and processes for producing the same. The pouch includes contoured first and second lateral edges, with each lateral edge having concave and convex surfaces. The concave surface of the first lateral edge is substantially opposite the convex surface of the second lateral edge and the convex surface of the first lateral edge is substantially opposite the concave surface of the second lateral edge. Accordingly, a distance between the first and second lateral edges is substantially the same for all elevations of the pouch.

FIELD OF THE INVENTION

[0001] The present invention relates to sealed pouches, and apparatusand processes for producing the same. In particular, the presentinvention relates to sealed pouches having contoured edges and a pourspout, and apparatus and processes for producing the same from one ormore films, laminates, or web materials.

BACKGROUND OF THE INVENTION

[0002] Pouches made from films or laminates, including polymers such aspolyethylene or polypropylene, have found use in a variety ofapplications. For example, such pouches are used to hold low viscosityfluids (e.g., juice and soda), high viscosity fluids (e.g., condimentsand sauces), fluid/solid mixtures (e.g., soups), gels, powders, andpulverulent materials. The benefit of such pouches resides, at least inpart, in the fact that such pouches are easy to store prior to fillingand produce very little waste when discarded. The pouches can be formedinto a variety of sizes and shapes. One type of pouch is designed to lieon a supporting surface and is generally known as a pillow-type pouch.Alternatively, pouches have been described which include a base thatpermits the pouch to maintain an upright configuration.

[0003] Pouches can be assembled from flexible films, laminates, or webmaterials using form-fill-seal machines. Such machines receive the film,laminate, or web material and manipulate the material to form thedesired shape. For example, one or more films, laminates, and/or webmaterials can be folded and oriented to produce the desired shape. Onceformed, the edges of the pouch are sealed and the pouch filled.Typically, the film, laminate, or web material has at least one heatseal layer or adhesive surface which enables the edges to be sealed bythe application of heat. During the sealing process, a portion of atleast one edge of the pouch is left unsealed until after the pouch isfilled. The pouch is filled through the unsealed portion and theunsealed portion is then sealed. Alternatively, the pouch can be filledand the unsealed portion simultaneously closed in order to provide asealed pouch with minimal headspace.

[0004] Although a variety of pouches have been previously described,none of the known pouches provides ergonomically contoured edges yet canbe manufactured on form-fill-seal machines without generatingappreciable, and preferably without generating any, scrap materialbetween subsequent pouches.

[0005] In light of the foregoing, it would be beneficial to provide apouch that is ergonomically designed to be easily handled and that isable to be produced, filled, and sealed on a form-fill-seal machinewithout generating appreciable, and preferably without generating any,scrap material between subsequent pouches.

SUMMARY OF THE INVENTION

[0006] The shortcomings of the known pouches are overcome, at least to alarge extent, by pouches in accordance with the present invention. Inparticular, the pouches of the present invention are ergonomicallydesigned to be contoured and, thereby, easy to hold. Additionally, thepouches in accordance with the present invention can be produced,filled, and sealed on a form-fill-seal machine without generating scrapmaterial between subsequent pouches.

[0007] In one of its aspects, the present invention relates to aflexible pouch comprising a first lateral edge and a second lateraledge. Each of the first and second lateral edges comprise concave andconvex surfaces or contours. The concave and convex surfaces arearranged such that the concave surface of the first lateral edge issubstantially opposite the convex surface of the second lateral edge andthe convex surface of the first lateral edge is substantially oppositethe concave surface of the second lateral edge. Alternatively, the firstlateral edge comprises a concave surface and the second lateral edgecomprises a convex surface, wherein the concave surface of the firstlateral edge is substantially opposite the convex surface of the secondlateral edge. In yet another embodiment, each of the first and secondlateral edges may comprise a non-rectilinear portion arranged such thata distance between the first and second lateral edges is substantiallythe same for all elevations of the pouch. In one particular embodiment,at least one of the first and second lateral edges is substantiallyS-shaped. Each of the first and second lateral edges may optionallycomprise at least one rectilinear portion positioned near the top orbottom of the pouch. The pouch may further optionally comprise a basefor supporting the pouch in an upright position.

[0008] The pouch is optionally configured with a pour spout. In oneembodiment the pour spout provides a drinking straw which enables fluidto be conveniently dispensed from the pouch. In another embodiment, thepour spout is formed from a first sealed edge portion and a secondsealed edge portion. A slit is formed within the first sealed edgeportion to facilitate tearing of the first sealed edge. The secondsealed edge portion contains a ribbed section and a non-ribbed section,wherein the non-ribbed section is substantially opposite the slit. Inyet another embodiment, the pour spout is formed at a corner of thepouch between the first and second sealed edge portions of the pouch. Asealed section extends between the first and second sealed edge portionsto define an opening. A slit is formed in the first sealed edge portionat a position intermediate the sealed section and the corner so that thedistance between the first edge portion at the location of the slit tothe second edge portion is not substantially less than the size of theopening.

[0009] In another of its aspects, the present invention relates to anapparatus for forming a pouch. The apparatus comprises a pouch formingcomponent for assembling the pouch. In one particular embodiment, thepouch forming component forms a pouch from a single web of pouch-formingmaterial. Bottom, top, and end sealing components are provided forsealing bottom, top, and lateral edges of the pouch, respectively. Ifdesired, the top sealing component may comprise a pour spout formingsection for forming a pour spout near the top edge of the pouch. The endsealing component is configured to provide a pouch with a lateral edgehaving a concave portion and a convex portion. In one particularembodiment, the end sealing component comprises a substantially S-shapedsealing surface. The end sealing component also optionally comprises arib forming portion for forming lateral edges having ribbed sections.The apparatus also includes a filling component for filling the pouchwith a fill material and a cutting component for cutting the lateraledge between subsequent pouches. The cutting component comprises acutting knife having a concave cutting surface and a convex cuttingsurface.

[0010] In yet another of its aspects, the present invention relates to aprocess for forming a pouch wherein the pouch is assembled from at leastone web of pouch-forming material. The assembled pouch is then sealedalong a bottom edge, a top edge, and a first lateral edge or margin. Thefirst lateral edge is sealed to provide a substantially S-shaped lateraledge. The pouch is then filled with a fill material and sealed along asecond substantially S-shaped lateral edge to provide a sealed pouch.The sealed pouch can then be cut along the second substantially S-shapedlateral edge.

[0011] Additional features and embodiments of the present invention willbecome apparent to those skilled in the art in view of the ensuingdisclosure and appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

[0012] The numerous objects and advantages of the present invention maybe better understood by those skilled in the art by reference to theaccompanying detailed description and the following drawings, in which:

[0013]FIG. 1 is a side elevational view of a pouch in accordance withthe present invention having contoured lateral edges;

[0014]FIG. 2 is side elevational view of the pouch of FIG. 1 shownconnected to adjacent pouches;

[0015]FIG. 3 is a side elevational view of a pouch in accordance withthe present invention having contoured lateral edges, a rounded topseal, and unsealed base sections, shown adjacent to a subsequent pouch;

[0016]FIG. 4 is a side elevational view of a pouch in accordance withthe present invention having contoured lateral edges, a rounded topseal, unsealed base sections, and a pour spout forming a drinking straw,shown adjacent to a subsequent pouch;

[0017]FIG. 5 is a side elevational view of the pouch shown in FIG. 4depicted in an unsealed and flattened configuration;

[0018]FIG. 6 is a side elevational view of the pouch of FIG. 4 having analternative arrangement for the pour spout;

[0019]FIG. 7 is a side elevational view of the pouch of FIG. 4 havinganother arrangement for the pour spout;

[0020]FIG. 8 is a side elevational view of the pouch of FIG. 4 havingyet another arrangement for the pour spout;

[0021]FIG. 9 is a side elevational view of the pouch of FIG. 4 havingstill another arrangement for the pour spout;

[0022]FIG. 10 is a side elevational view of a pouch in accordance withthe present invention having a pour spout;

[0023]FIG. 11 is a schematic view of an apparatus in accordance with thepresent invention for producing a pouch;

[0024]FIG. 12a is a front elevational view of an end seal bar inaccordance with the present invention;

[0025]FIG. 12b is a side elevational view of the end seal bar of FIG.12a;

[0026]FIG. 13a is a front elevational view of an end seal backing bar inaccordance with the present invention;

[0027]FIG. 13b is a side elevational view of the end backing seal bar ofFIG. 13a;

[0028]FIG. 14a is a front elevational view of a cutting bar inaccordance with the present invention;

[0029]FIG. 14b is a side elevational view of the cutting bar of FIG.14a;

[0030]FIG. 15a is a front elevational view of a cutting blade inaccordance with the present invention;

[0031]FIG. 15b is a top elevational view of the cutting blade of FIG.15a;

[0032]FIG. 16a is a front elevational view of a cooling bar inaccordance with the present invention;

[0033]FIG. 16b is a side elevational view of the cooling bar of FIG.16a;

[0034]FIG. 17 is a front elevational view of a top seal bar inaccordance with the present invention;

[0035]FIG. 18 is a perspective view of a bottom seal bar in accordancewith the present invention; and

[0036]FIG. 19 is a perspective view of the pouch of FIG. 1.

DETAILED DESCRIPTION OF THE INVENTION

[0037] A pouch in accordance with one embodiment of the presentinvention is depicted in FIGS. 1 and 19. The pouch 20 comprises a frontpanel 21, a rear panel 22, and an optional gusset 23. The optionalgusset 23 is provided to produce a free-standing pouch. Each of thefront and rear panels has a top edge, a bottom edge, a left lateral edgeor margin, and a right lateral edge or margin. The front and rear panelsare generally arranged such that each edge of one panel is substantiallyaligned with the corresponding edge of the other panel. Accordingly, thefront and rear panels 21, 22 are arranged to produce the pouch 20 with atop edge 24, a bottom edge or edges 25, a left lateral edge or margin26, and a right lateral edge or margin 27.

[0038] The left and right lateral edges 26, 27 of the pouch 20 arecontoured. As shown in FIG. 1, each of the left and right lateral edges26, 27 is shaped to provide a concave surface 30 and 130, respectively,and a convex surface 31 and 131, respectively. The concave surface 30 ofthe left lateral edge 26 is substantially opposite the convex surface131 of the right lateral edge 27 and the convex surface 31 of the leftlateral edge 26 is substantially opposite the concave surface 130 of theright lateral edge 27. Accordingly, the concave and convex surfaces ofeach lateral edge taken together form a non-rectilinear and, preferably,a generally S-shaped section. It will be appreciated by those skilled inthe art that a distance between the left and the right lateral edges 26,27 is substantially the same for all elevations of the pouch 20.

[0039] In addition, each of the left and the right lateral edges 26, 27of the pouch 20 comprises optional first and second rectilinear portions32, 33. The first rectilinear portion 32 of each lateral edge 26, 27 ispositioned near the top edge 24 of the pouch 20. The second rectilinearportion 33 of each lateral edge 26, 27 is similarly positioned near thebottom edge 25 of the pouch 20. When the pouch 20 is configured to befree-standing, as shown, the second rectilinear portions 33 enhance thestability of the pouch when the pouch is filled and in its uprightposition.

[0040] The front panel 21, rear panel 22, and gusset 23 can be formedfrom any of a variety of films, laminates, or web materials, so long asthe material is suitably flexible and capable of providing sufficientstructural integrity. For example, the front panel 21, rear panel 22 andgusset 23 can be manufactured out of paper, paper composites, metallicfilms, co-extruded polymer films (such as FS-5150 and FS-5050 availablefrom Cryovac/Sealed Air Corp, Duncan, S.C.), or laminated polymer films.In one embodiment, the front panel 21, rear panel 22, and gusset 23 areformed from a polyolefinic material having a thickness of between about0.001 and about 0.01 inches (0.025-0.25 mm), and preferably betweenabout 0.003 and about 0.006 inches (0.076-0.152 mm).

[0041] The front panel 21, rear panel 22, and gusset 23 are sealed alongthe top, bottom, and lateral edges 24, 25, 26, 27 to form an innercavity 35. In order to provide a base for the pouch 20, portions 36 ofthe gusset 23 are sealed to the front and rear panels 21, 22. As shownin FIG. 1, the portions 36 of the gusset 23, which are sealed to thefront and rear panels 21, 22, present a generally arcuate seal to theinterior of the inner cavity 35 of the pouch 20. When the pouch 20 isfilled and placed in an upright position, an unsealed portion 37 of thegusset 23 can deform to form the bottom of the inner cavity 35 of thepouch 20, as best shown in FIG. 19. The inner cavity 35 is capable ofholding a variety of materials, including low viscosity fluids (such aswater, juice, and soda), high viscosity fluids (such as condiments andsauces), fluid/solid mixtures (such as soups), gels, powders, andpulverulent materials. Sealing can be accomplished using any of avariety of conventional methods, including the use of conventionaladhesives and/or heat sealing. Further, the seals produced can be eithersmooth or ribbed, as described in more detail below.

[0042] In FIG. 2, a series of pouches 20 of the type shown in FIG. 1 isillustrated. It is apparent from FIG. 2 that the left lateral edge 26 ofone pouch matches perfectly with the right lateral edge 27 of asubsequent pouch. As a result, the pouch of FIG. 1 can be producedusing, for example, form-fill-seal machines without generating any scrapmaterial. Accordingly, the amount of material needed per pouch isreduced, thereby reducing the cost of producing each pouch.

[0043] In FIG. 3, an alternative embodiment of a pouch in accordancewith the present invention is depicted. The pouch 220 is in manyrespects identical to the pouch 20 described above in connection withFIG. 1. However, the top edge 224 of the pouch 220 of FIG. 3 is sealedto provide rounded corners 238 near the junctions made by the top edge224 with the left and right lateral edges 226, 227. In addition, theportions 236 of the gusset 223 which are sealed to the front and rearpanels comprise unsealed sections 239, as described in detail below withrespect to unsealed sections 339 of pouch 320 in FIGS. 4 and 5.

[0044] Yet another embodiment of a pouch in accordance with the presentinvention is shown in FIG. 4. The pouch 320 of FIG. 4 is identical tothe pouch 220 of FIG. 3, except that the pouch 320 comprises a pourspout 345 formed near the junction of the top edge 324 and the rightlateral edge 327 of the pouch 320. The pour spout 345 is formed from asealed section 346 extending generally between the top edge 324 and theright lateral edge 327 of the pouch 320. The sealed section 346 isshaped to provide a channel 347 which is in fluid communication with theinner cavity 335 of the pouch 320 at one end. The other end of thechannel 347 extends generally away from the inner cavity 335 toward acorner 338 of the pouch 320. Accordingly, the pour spout 345 provides adrinking straw which can be used to dispense fluids out of the innercavity 335 of the pouch 320 either by sucking on the straw or bysqueezing the pouch to force the fluid from the pouch.

[0045] An optional slit or notch 348 is provided within the top edge 324of the pouch 320 to facilitate opening of the pour spout 345. When theright lateral edge 327 of the pouch 320 is to be ribbed, the rightlateral edge 327 optionally contains a non-ribbed section 349substantially opposite the slit 348. The slit 348 and non-ribbed section349 cooperate to allow the corner 338 of the pouch 320 to be torn orremoved to open the pour spout 345, while preventing the tear fromexposing the inner cavity 335 of the pouch 320.

[0046] In order to better appreciate the construction of the pouch 320of FIG. 4, FIG. 5 is provided to depict a partially manufactured pouchof FIG. 4, shown in an unsealed and flattened configuration. The hatchedportions of FIG. 5 denote those sections of the front panel 321, rearpanel 322, and gusset 323 which are sealed in the finished pouch. FIG. 5shows how the generally rectangular gusset 323 is folded to form thebase of the pouch 320 when the gusset 323 is overlapped with the frontand rear panels 321, 322. The gusset 323 is folded along itslongitudinal axis to provide a V-shape having a folded edge 351 and twosingle or open edges 352, 353. The gusset 323 is positioned between thefront and rear panels 321, 322 with one open edge 352 substantiallyoverlapping the bottom edge of the front panel 321 and the second openedge 353 substantially overlapping the bottom edge of the rear panel322. The folded edge 351 of the gusset 323 is positioned such that afirst end 354 of the folded edge 351 intercepts the left edge 326 of thepouch 320 at a preselected position between the top and bottom edges324, 325 of the pouch 320. Similarly, a second end 355 of the foldededge 351 intercepts the right edge 327 of the pouch 320 at about thesame preselected position between the top and bottom edges 324, 325 ofthe pouch 320.

[0047]FIG. 5 also shows unsealed sections 339 which are formed whenportions 336 of the gusset 323 are sealed to the front and rear panels321, 322. By providing unsealed sections 339, the amount of adhesive orheat required to seal the gusset 323 to the front and rear panels 321,322 is reduced. The use of less adhesive results in a decrease inproduction cost. In addition, when the panels are heat sealed, less heatresults in less deformation of the pouch material and, hence, a superiorfinished product.

[0048] Also apparent from FIG. 5 is that the front panel 321, rear panel322, and gusset 323 of the pouch 320 can be made either from individualsections of web material or from a single piece of folded web material.It will be apparent that when the front panel 321, rear panel 322, andgusset 323 are made from a single piece of web material that the edges,352 and 353, are integrally formed with the bottom edges of the frontand rear panels, 321 and 322 respectively. Accordingly, front and rearpanels 321, 322 are made to oppose one another by folding.

[0049]FIG. 5 additionally illustrates optional cutouts 356 which can beprovided in the lateral edges 357 of the gusset 323. The cutouts 356 areparticularly beneficial when the pouch 320 is made from a single sectionof laminate material having a heat seal layer or adhesive along only oneof its surfaces. Under such conditions, the cutouts 357 enable the heatseal layer or adhesive surface of the front panel 321 to directlycontact the heat seal layer or adhesive surface of the rear panel 322,thereby providing a more secure seal.

[0050] FIGS. 6-10 depict pouches in accordance with the presentinvention which are identical to the pouch shown in FIG. 1, except thatthe pouches of FIGS. 6-10 comprise a pour spout 445, 545, 645, 745, 845.In each of the pouches of FIGS. 6-10, the pour spout is formed from asealed portion which extends generally between the top edge and theright and/or left lateral edges of the pouch. In FIG. 6, the pour spout445 is formed as a channel 447 which extends from the inner cavity 435of the pouch 420 generally toward the center of the top edge 424 of thepouch 420. The pour spout 545 of FIG. 8 is in many respects similar tothe pour spout 445 shown in FIG. 6. However, the pour spout 545 of FIG.8 extends vertically toward a corner 538 of the pouch 520. As can bereadily seen by comparing FIG. 8 with FIG. 6, a pouch having the pourspout 545 of FIG. 8 holds more fluid than a similarly sized pouch havingthe pour spout 445 of FIG. 6. In FIG. 7, the pour spout 645 is formed asa channel 647 which extends generally away from the inner cavity 635toward a corner 638 of the pouch 620. The end of the channel 647 nearestthe corner 638 of the pouch 620 is shaped to form a generally triangularsection 658. The triangular section 658 enables the pour spout 645, whenopened, to provide a dispensing orifice which is wider than the channel647. Such a dispensing opening is able to flare out as fluid isdispensed therethrough, thus facilitating removal of the fluid from thepouch 620. The pour spouts 745, 845 of FIGS. 9 and 10 are essentiallythe same as the pour spout 645 shown in FIG. 7. However, the pour spouts745, 845 of FIGS. 9 and 10 differ from each other, and from the pourspout 645 of FIG. 7, in the relative dimensions of the channel 747, 847(i.e., the length and width of the channel) and the size of thetriangular section 758, 858. The pour spouts 645, 745, 845 of FIGS. 7,9, and 10 are particularly well suited for dispensing high viscosityfluids.

[0051] The present invention further relates to an apparatus forproducing a contoured pouch having a pour spout. A preferred apparatus965 for use in connection with the present invention is shownschematically in FIG. 11 and described in, for example, publishedEuropean Patent Application No. 98402857.1 (Publication No. EP 0 917946), which is hereby incorporated by reference in its entirety. Inbrief, the apparatus 965 is a vertical form-fill-seal machine comprisinga folding mechanism 966, a first sealing mechanism 967, and a secondsealing mechanism 968. The folding mechanism 966 receives a pouchmaterial from a roll or web 969 and folds the pouch material to providea front panel, a rear panel, and a gusset. The folded web material isthen fed into the first sealing mechanism 967 where the front and rearpanels are heat sealed along a straight line at their top edges using atop seal bar and the gusset is sealed to the front and rear panels usinga bottom seal bar. The web material is then fed to the second sealingmechanism 968 where one of the lateral edges of the front and rearpanels are sealed together along a straight line using an end seal bar,the inner cavity of the pouch is filled with fluid, and the otherlateral edge of the front and rear panels is sealed and cut along astraight line using a cutting bar. In the particular apparatus describedin European Patent Application No. 98402857.1, squeeze rollers areprovided to minimize the headspace within the sealed pouches. However,it will be appreciated that any of a variety of conventional machines,including pillow-type pouch forming machines, can also be used inconnection with the present invention.

[0052] The present inventor has recognized that the apparatus describedin European Patent Application No. 98402857.1 can be modified to producepouches in accordance with the present invention. Toward that end, a topseal bar 972, useful for producing pouches of the type shown in FIGS. 4and 5, is depicted in FIG. 17. As can be seen from the figure, the topseal bar 972 comprises raised portions 973 which are shaped to providethe pour spout and the rounded corners that are part of the finalproduct. Similar top seal bars can be constructed for the other pouchconfigurations described above.

[0053] A bottom seal bar 974 for producing pouches as depicted in FIGS.3-5 is shown in FIG. 18. The bottom seal bar 974 comprises a raisedportion 975 which seal the gusset to the front and rear panels. The sealbar 974 produces unsealed sections of the gusset, similar to unsealedsections 239 shown, for example, in FIG. 3. It will be appreciated thatsimilar bottom seal bars could be produced to provide for alternativesealing configurations, such as the configurations depicted in otherembodiments of the present invention.

[0054] An end seal bar 976 for producing pouches having contouredlateral edges in accordance with the present invention is depicted inFIGS. 12a and 12 b. The end seal bar 976 comprises a raised portion 977which is shaped to provide a concave surface and a convex surface. Theconcave and convex surfaces form a non-rectilinear and, preferablygenerally S-shaped section. The end seal bar 976 also optionallycomprises raised rectilinear portions 978 positioned near those sectionsof the end seal bar 976 which will form the top and bottom edges of thepouch. Although the body of the end seal bar 976 is depicted as arectangular block, it will be appreciated that the body of the end sealbar 976 can be shaped similarly to the raised portion 977.

[0055] As shown, the raised portions 973, 975, 977 of the top, bottomand end seal bars 972, 974, 976 present a smooth surface. However, theraised portions may comprise two or more raised ribs. The raised ribscreate a ribbed seal which, in certain instances, can be desired over asmooth seal. For example, when the pouch is to contain a more viscousfluid or a substance having solid parts (such as seeds), fluid or solidstrapped between the edges of the front and rear panels of the pouch arepushed out of the way by the raised ribs during sealing and, thus, donot interfere with the sealing process. Additionally, the ribbed sealsprovide added rigidity to the pouch, which may be desired when astand-up pouch is produced.

[0056] A cutting bar 979 for producing pouches having contoured lateraledges in accordance with the present invention is depicted in FIGS. 14aand 14 b. The cutting bar 979, like the end seal bar 976, comprises araised portion 980 shaped to provide a concave surface and a convexsurface which form a non-rectilinear and, preferably, generally S-shapedsection. The cutting bar 979 also optionally comprises raisedrectilinear portions 981 positioned near those sections of the cuttingbar 979 which will form the top and bottom edges of the pouch. Inparticular, the cutting bar 979 is shaped and arranged, relative to theend seal bar 976, within the apparatus 965 of FIG. 11 such that theraised portion 980 of the cutting bar 979 lies substantially along theseal produced by the end seal bar 979 when adjacent pouches are beingseparated. Although the body of the cutting bar 979 is depicted as arectangular block, it will be appreciated that the body of the cuttingbar 979 can be shaped similarly to the raised portion 980.

[0057] The cutting bar 979 also comprises a curved blade 984 positionedwithin a groove 985. The curved blade 984 is used to sever each pouchfrom adjacent pouches. The cutting blade 984 is depicted in FIGS. 15aand 15 b. The blade 984, like the raised portions 980, 977 of thecutting and end seal bars 979, 976, also contains concave and convexsurfaces, as well as optional rectilinear surfaces. Specifically, theconcave, convex, and rectilinear surfaces of the blade 984 are sized andshaped to fit within the groove 985. As shown in FIG. 15a, the blade 984may optionally be tapered along its longitudinal axis. Tapering ensuresthat the wider end of the blade 984 contacts the pouch material firstduring cutting of the pouches. Cutting the pouches from one end towardthe other provides a smoother cutting motion and, thus, results in abetter finished product. The blade 984 may further contain teeth (notshown) to facilitate cutting. The blade 984 may be formed by bending aflat section of material, such as stainless steel. Alternatively, theblade 984 may be laser cut from a solid bar of material in order toprovide a smoother contour.

[0058] The top seal, bottom seal, end seal, and cutting bars 972, 974,976, 979 can be made from a variety of materials. For example, the barscan be manufactured from aluminum, brass, or steel. Further, the barscan optionally be Teflon® coated. To provide optimum contact between thesealing bars 972, 974, 976 and the pouch, each of the sealing bars 972,974, 976 “mates” with a corresponding seal backing bar. Each sealbacking bar is preferably configured as the mirror image of itscorrelating sealing bar 972, 974, 976, so that when the seal backing barand its corresponding sealing bar are mated with the pouch materialtherebetween, the seal backing bar provides uniform contact between thesealing bar and the pouch material. For example, an end seal backing baris shown in FIGS. 13a and 13 b. End seal backing bar 989 is configuredto mate with end seal bar 976. Toward that end, the seal backing bar 989preferably has a raised portion 990 made of a resilient material such asrubber. Alternatively, the raised portions 990 of the end seal backingbar 989 can be generally rectangular provided that the raised portion990 of the end seal backing bar 989 provides uniform contact between thesealing bar 976 and the pouch material over substantially all of thesurface of the raised portion 977 of the end seal bar 976. Although thebody of the end seal backing bar 989 is depicted as a rectangular block,it will be appreciated that the bodies of the seal backing bars can beshaped similarly to the raised portions.

[0059] Similar to the seal backing bars is the cutting backing bar 993depicted in FIGS. 16a and 16 b. The cutting backing bar 993 has a raisedportion 994 that is generally shaped as the mirror image of the cuttingbar 979. Alternatively, the raised portion 994 of the cutting backingbar 993 can be generally rectangular, provided that the cutting backingbar 993 provides uniform contact between the cutting bar 979 and thepouch material over substantially all of the surface of the raisedportion 980 of the cutting bar 979. However, instead of the blade 984,the cutting backing bar 993 comprises a groove 995 for receiving theblade 984 of the cutting bar 979 when the cutting backing bar 993 andthe cutting bar 979 are mated. In one embodiment, the cutting backingbar 993 is further provided with a source of coolant, such as flowingwater, in order to cool the sealed pouch material during cutting and,thereby, provide a superior seal. Although the body of the cuttingbacking bar 993 is depicted as a rectangular block, it will beappreciated that the body of the cutting backing bar 993 can be shapedsimilarly to the raised portion.

[0060] In operation, a pouch according to the present invention can beformed by assembling the pouch from at least one web of pouch-formingmaterial on a vertical form-fill-seal machine. The pouch is preferablyassembled using a folding mechanism to fold a single web ofpouch-forming material into the shape of the pouch. Alternatively, thefront panel, rear panel, and optional gusset of the pouch can beassembled as individual pieces fabricated from two or more webs.

[0061] A top edge, a bottom edge, and a first lateral edge of the pouchare then sealed. The bottom edge is sealed using the bottom seal bar andbottom backing bar. Similarly, the top edge is sealed using the top sealbar and top backing bar The first lateral edge of the pouch is alsosealed, using the end seal bar and end backing bar, to provide asubstantially S-shaped lateral edge. It will be appreciated that thetop, bottom, and first lateral edges can be sealed in any order.

[0062] The pouch is then filled with a fill material and a secondlateral edge of the pouch sealed, using the same or different end sealand end backing bars, to provide a substantially S-shaped second lateraledge. It will be apparent that the filling and second lateral edgesealing steps can occur simultaneously. The sealed and filled pouch canbe cut, using the cutting and cutting backing bars, along thesubstantially S-shaped second lateral edge.

[0063] Those skilled in the art will appreciate that numerous changesand modifications may be made to the preferred embodiments of theinvention and that such changes and modifications may be made withoutdeparting from the spirit of the invention. For example, although thepresent invention has been described in connection with a stand-uppouch, the present invention is also applicable for use with other typesof pouches, including pillow-type pouches. Further, although theapparatus of the present invention has been described in connection witha vertical form-fill-seal machine, the present invention is equallyapplicable for use in horizontal machines. It is therefore intended thatthe appended claims cover all equivalent variations as fall within thetrue scope and spirit of the invention.

What is claimed is:
 1. A pouch comprising opposing flexible panelshaving first and second lateral edges, a bottom edge, and a top edge, atleast the first lateral edge and the second lateral edge being sealed,defining an inner cavity; each of the first and the second lateral edgescomprising a concave surface and a convex surface, wherein the concavesurface of the first lateral edge is substantially opposite the convexsurface of the second lateral edge and the convex surface of the firstlateral edge is substantially opposite the concave surface of the secondlateral edge.
 2. The pouch of claim 1 wherein at least one of the firstand the second lateral edges is substantially S-shaped.
 3. The pouch ofclaim 1 wherein each of the first and the second lateral edges comprisesat least one rectilinear portion.
 4. The pouch of claim 3 wherein saidat least one rectilinear portion of each of the first and the secondlateral edges is positioned near a top of the pouch.
 5. The pouch ofclaim 3 wherein said at least one rectilinear portion of each of thefirst and the second lateral edges is positioned near a bottom of thepouch.
 6. The pouch of claim 1 wherein each of the first and the secondlateral edges comprises a first rectilinear portion and a secondrectilinear portion, the first rectilinear portion of each lateral edgebeing positioned near a top of the pouch and the second rectilinearportion of each lateral edge being positioned near a bottom of thepouch.
 7. The pouch of claim 1 comprising a base for supporting thepouch in an upright position.
 8. The pouch of claim 7 wherein the basecomprises a curved section.
 9. The pouch of claim 1 comprising a pourspout defined by a channel in a sealed edge of the pouch communicatingwith the inner cavity of the pouch.
 10. The pouch of claim 9 wherein thechannel defines a drinking straw.
 11. The pouch of claim 9 wherein thepour spout comprises a first sealed edge portion, a slit positioned inthe first sealed edge portion, and a second sealed edge portion having aribbed section and a non-ribbed section, the non-ribbed section of thesecond sealed edge portion being substantially opposite the slit.
 12. Apouch comprising opposing flexible panels having first and secondlateral edges, a bottom edge, and a top edge, at least the first lateraledge and the second lateral edge being sealed, defining an inner cavity;and a pour spout defined by a channel in a sealed edge of the pouchcommunicating with the inner cavity of the pouch; wherein each of thefirst and the second lateral edges comprises a concave surface, a convexsurface, and at least one rectilinear portion positioned near a bottomof the pouch, and wherein the concave surface of the first lateral edgeis substantially opposite the convex surface of the second lateral edgeand the convex surface of the first lateral edge is substantiallyopposite the concave surface of the second lateral edge.
 13. A pouchcomprising opposing flexible panels having first and second lateraledges, a bottom edge, and a top edge, at least the first lateral edgeand the second lateral edge being sealed, defining an inner cavity; thefirst lateral edge comprising a concave surface and the second lateraledge comprising a convex surface, wherein the concave surface of thefirst lateral edge is substantially opposite the convex surface of thesecond lateral edge.
 14. A pouch comprising opposing flexible panelshaving first and second lateral edges, a bottom edge, and a top edge, atleast the first lateral edge and the second lateral edge being sealed,defining an inner cavity; each of the first and the second lateral edgescomprising a non-rectilinear portion, wherein a distance between thefirst and the second lateral edges is substantially the same for allelevations of the pouch.
 15. The pouch of claim 14 wherein at least oneof the first and the second lateral edges is substantially S-shaped. 16.The pouch of claim 14 wherein each of the first and the second lateraledges comprises at least one rectilinear portion.
 17. The pouch of claim16 wherein said at least one rectilinear portion of each of the firstand the second lateral edges is positioned near a top of the pouch. 18.The pouch of claim 16 wherein said at least one rectilinear portion ofeach of the first and the second lateral edges is positioned near abottom of the pouch.
 19. The pouch of claim 14 wherein each of the firstand the second lateral edges comprises a first rectilinear portion and asecond rectilinear portion, the first rectilinear portion of eachlateral edge being positioned near a top of the pouch and the secondrectilinear portion of each lateral edge being positioned near a bottomof the pouch.
 20. The pouch of claim 14 comprising a base for supportingthe pouch in an upright position.
 21. The pouch of claim 20 wherein thebase comprises a curved section.
 22. The pouch of claim 14 comprising apour spout defined by a channel in a sealed edge of the pouchcommunicating with the inner cavity of the pouch.
 23. The pouch of claim22 wherein the channel defines a drinking straw.
 24. The pouch of claim22 wherein the pour spout comprises a first sealed edge portion, a slitpositioned in the first sealed edge portion, and a second sealed edgeportion having a ribbed section and a non-ribbed section, the non-ribbedsection of the second sealed edge portion being substantially oppositethe slit.
 25. A pouch comprising opposing flexible panels having firstand second lateral edges, a bottom edge, and a top edge, at least thefirst lateral edge and the second lateral edge being sealed, defining aninner cavity; and a pour spout defined by a channel in a sealed edge ofthe pouch communicating with the inner cavity of the pouch; wherein eachof the first and the second lateral edges comprises a non-rectilinearportion and at least one rectilinear portion positioned near a bottom ofthe pouch, and wherein a distance between the first and the secondlateral edges is substantially the same for all elevations of the pouch.26. A pouch comprising opposing flexible panels having first and secondlateral edges, a bottom edge, and a top edge, at least the first lateraledge and the second lateral edge being sealed, defining an inner cavity;a first sealed edge portion; a slit positioned in the first sealed edgeportion; and a second sealed edge portion having a ribbed section and anon-ribbed section, the non-ribbed section of the second sealed edgeportion being substantially opposite the slit.
 27. The pouch of claim 26wherein the slit comprises a notched section.
 28. A pouch comprisingopposing flexible panels having first and second lateral edges, a bottomedge, and a top edge, at least the first lateral edge and the secondlateral edge being sealed, defining an inner cavity; a first sealed edgeportion; a second sealed edge portion adjoining the first sealed edgeportion to form a corner; a sealed section extending generally betweenthe first sealed edge portion and the second sealed edge portion todefine an opening; and a slit formed in the first sealed edge portion ata position intermediate the sealed section and the corner such that thedistance between the first edge portion at the location of the slit tothe second edge portion is not substantially less than the size of theopening.
 29. An apparatus for forming a pouch comprising: a. a pouchforming component for assembling the pouch from at least one web ofpouch-forming material; b. a bottom sealing component for sealing abottom edge of the pouch; c. a top sealing component for sealing a topedge of the pouch; d. an end sealing component for sealing a lateraledge of the pouch to provide a lateral edge having a concave portion anda convex portion; e. a filling component for filling the pouch with afill material; and f. a cutting component for cutting the lateral edgealong the concave and convex portions.
 30. The apparatus of claim 29wherein the pouch forming component forms a pouch having a front panel,a rear panel, and a base from a single web of pouch-forming material.31. The apparatus of claim 30 wherein the pouch-forming component formsthe base as a gusset positioned between the front panel and the rearpanel of the pouch.
 32. The apparatus of claim 29 wherein the topsealing component comprises a pour spout forming section for forming apour spout near the top edge of the pouch.
 33. The apparatus of claim 32wherein the top sealing component comprises a slit forming component.34. The apparatus of claim 32 wherein the top sealing componentcomprises a notch forming component.
 35. The apparatus of claim 29wherein the end sealing component comprises a rib forming portion forforming the lateral edge with a ribbed section.
 36. The apparatus ofclaim 35 wherein the rib forming portion is positioned along the endsealing component such that the ribbed section of the lateral edgeterminates at a preselected distance from the top edge of the pouch. 37.The apparatus of claim 29 wherein the cutting component comprises acutting knife having a concave cutting surface and a convex cuttingsurface.
 38. A process for forming a pouch comprising: a. assembling thepouch from at least one web of pouch-forming material; b. sealing abottom edge of the pouch; c. sealing a top edge of the pouch; d. sealinga first Lateral edge of the pouch to provide a lateral edge having aconcave portion and a convex portion; e. filling the pouch with a fillmaterial; f. sealing a second lateral edge of the pouch to provide alateral edge having a concave portion and a convex portion; and g.cutting the second lateral edge along the concave and convex portions.39. An apparatus for forming a pouch comprising: a. a pouch formingcomponent for assembling the pouch from at least one web ofpouch-forming material; b. a bottom sealing component for sealing abottom edge of the pouch; c. a top sealing component for sealing a topedge of the pouch; d. an end sealing component for sealing a lateraledge of the pouch to provide a substantially S-shaped lateral edge; e. afilling component for filling the pouch with a fill material; and f. acutting component for cutting along the substantially S-shaped lateraledge.
 40. The apparatus of claim 39 wherein the pouch forming componentforms a pouch having a front panel, a rear panel, and a base from asingle web of pouch-forming material.
 41. The apparatus of claim 40wherein the pouch-forming component forms the base as a gussetpositioned between the front panel and the rear panel of the pouch. 42.The apparatus of claim 39 wherein the top sealing component comprises apour spout forming section for forming a pour spout near the top edge ofthe pouch.
 43. The apparatus of claim 42 wherein the top sealingcomponent comprises a slit forming component.
 44. The apparatus of claim42 wherein the top sealing component comprises a notch formingcomponent.
 45. The apparatus of claim 39 wherein the end sealingcomponent comprises a rib forming portion for forming the lateral edgewith a ribbed section.
 46. The apparatus of claim 45 wherein the ribforming portion is positioned along the end sealing component such thatthe ribbed section of the lateral edge terminates at a preselecteddistance from the top edge of the pouch.
 47. The apparatus of claim 39wherein the cutting component comprises a cutting knife having asubstantially S-shaped cutting surface.
 48. A process for forming apouch comprising: a. assembling the pouch from at least one web ofpouch-forming material; b. sealing a bottom edge of the pouch; c.sealing a top edge of the pouch; d. sealing a first lateral edge of thepouch to provide a substantially S-shaped lateral edge; e. filling thepouch with a fill material; f. sealing a second lateral edge of thepouch to provide a substantially S-shaped lateral edge; and g. cuttingalong the substantially S-shaped second lateral edge.
 49. The process ofclaim 48 wherein the filling and second lateral edge sealing steps occursimultaneously.